4.2. Repair

Dismantling of a forward spring suspension bracket
Replacement of springs of vibration-absorbing laying and buffers:

Fig. 236. Forward suspension bracket: 1 – laying is vibration-absorbing; 2, 17 – spring arms;
3 – shock-absorber; 4, 21 – hinges rubber-metal; 5, 10 – nuts; 6 – step-ladder; 7, 8 – plugs rubber; 9, 16 – arms of the longitudinal lever; 11 – washer; 12 – hinges rubber; 13 – stabilizer arm; 14 – stabilizer; 15 – longitudinal bar; 18 – spring; 19 – buffer; 20, 23 – arms of cross draft; 22 – cross draft

1. Disconnect the lower eyes of shock-absorbers 3 (see fig. 236) from longitudinal bars 15, having turned off nuts and having taken out bolts.
2. Lift and establish a forward part of the car on a support.
3. Remove springs 18 and vibration-absorbing laying 1.
4. Turn off bolts of fastening of buffers 19.
5. You carry out assembly upside-down.

At impossibility to take out or insert a spring it is necessary to disconnect in addition one of the ends of cross draft.

Replacement of rubber-metal hinges, basic plugs of longitudinal bars and rubber plugs of the stabilizer:
1. Reliably fix the car from spontaneous movement.
2. Disconnect the lower eyes of shock-absorbers from longitudinal bars 15 (see fig. 236), having turned off nuts and having taken out bolts.
3. Turn off nuts 5 and beat out bolts of fastening of a longitudinal bar to the bridge.
4. Rasshplintuyte also turn off nuts 10.
5. Turn off nuts of step-ladders of the 6th fastening of the stabilizer to a bar.
6. Remove longitudinal bars, having brought the back end of a bar out of an arm opening on a frame.
7. Turn off bolts of fastening of the stabilizer to an arm 13.
8. Replace rubber-metal hinges 4. Replacement of hinges is made by means of special mandrels on the press equipment. It is necessary to replace at the same time all hinges.
9. Remove plugs 7 from the stabilizer and put on new.
10. Replace plugs 8 and wrap bolts of fastening of the stabilizer to an arm 13.
11. Put on a washer and the basic rubber hinge 12 the back end of a bar 15, insert a bar into an opening of an arm 9, put on the second rubber hinge 12 and a washer 11, "acquire" a nut 10.
12. Insert the forward end of a bar into an arm 16, establish new bolts and "acquire" nuts 5.
13. Similarly establish the second bar.
14. Tighten nuts the 5th moment of 140-160 N • m (14–16 kgfs • м). Tighten against the stop nuts 10 and their zashplintuyta.
15. Establish step-ladders of the 6th fastening of the stabilizer to a bar and tighten nuts of step-ladders.
16. Connect the lower eyes of shock-absorbers to longitudinal bars, having inserted bolts and having wrapped nuts.
Replacement of cross draft or its rubber-metal hinges:
1. Turn off a bolt and a nut of fastening of cross draft 22 to the bridge and a frame.
2. Remove cross draft.
3. Replace hinges similar to hinges of longitudinal bars.
4. Establish draft and fix it, using new bolts.
5. A nut and a bolt tighten the moment of 140-160 N · m (14–16 kgfs · м).

Removal, dismantling and assembly of a back suspension bracket
Remove a back spring in the following order:

Fig. 237. Back suspension bracket: 1, 10 – a shock-absorber arm; 2 – spring; 3 – shock-absorber; 4 – frame;
5 – slip; 6 – step-ladder; 7 – lining of step-ladders; 8 – earring arm; 9 – spring lining;
11 – step-ladder nut; 12 – axis; 13 – plug rubber; 14 – buffer; 15 – earring cheek internal; 16 – finger; 17 – earring cheek external; 18 – finger nut

1. Turn off nuts of 11 step-ladders 6 (see fig. 237) springs, remove stre-myanka, a lining 7 and a slip 5.
2. Lift and establish a back part of the car on a support.
3. Turn off bolts of fastening of an arm 8 and a nut of axis 12 of an eye of a spring.
4. Remove a spring 2 and sort an earring with rubber plugs 13. If necessary replace worn-out details.
5. Remove a lining 9.
You carry out installation of a spring in the return order.
At installation of springs on the car the bent eyes on the first two sheets have to be turned forward.
Finally tighten nuts of step-ladders of springs at the loaded springs.
You carry out dismantling of a spring in the following order:
1. Clamp a spring in a vice with soft sponges so that to unload a center bolt.
2. Unbend collars of springs.
3. Turn off a nut of a center bolt, gradually weaken a vice and sort a spring.
After dismantling carefully clear sheets of dirt, wash out in kerosene, replace the broken sheets.
You carry out assembly of a spring in the return order taking into account the following:
1. Collars reliably priklepayte to sheets, end faces of rivets of collars should not act over a surface of sheets.
2. Collars after assembly of a spring should not interfere with free moving of sheets to work time.
3. After assembly paint a spring.

Dismantling, assembly and filling of the shock-absorber
You carry out dismantling of the shock-absorber in the following order:

Fig. 238. Shock-absorber: 1 – eye; 2 – compression valve limiter; 3 – compression valve case; 4 – compression valve; 5 – inlet valve; 6 – tank; 7 – cylinder; 8 – return valve; 9 – piston; 10 – perepuskny valve; 11 – rod; 12 – casing;
13 – the directing rod plug; 14 – lower sealing ring; 15 – epiploon; 16 – top sealing ring; 17 – holder of epiploons;
18 – tank nut; 19 – washer; 20 – protective ring; 21 – rod epiploon; 22 – the release buffer (only for forward shock-absorbers)

Fig. 239. The key sizes for a shock-absorber tank nut otvorachivaniye

1. Fix the shock-absorber for the lower assembly eye 1 in a vice, a feather-mestite the piston 9 (see fig. 238) in the top situation. Then a key (fig. 239) turn off a nut of the 18th tank 6.
2. Easy rocking for the top end take out a rod 11 together with the piston from the working cylinder. Thus be especially attentive not to damage the polished rod surface.
3. Take out the working cylinder 7 from the tank and completely merge damping liquid.
4. Fix a rod in a vice for the top assembly eye, turn off a piston nut. Remove the piston with valvate details, a guide 13 and I will embrace 17 epiploons.
Wash out all details of the shock-absorber in gasoline or kerosene. Carefully examine the washed-out and dried up details and reveal those which are subject to correction or replacement.
At survey of details of valvate knots pay special attention to a condition of working edges. At existence on the locking surface of the valve or on its saddle risok, traces of considerable wear and other defects eliminate them with grinding in. Replace details of valves on which at survey you will find cracks and breaks.
You carry out assembly of the shock-absorber in the return order taking into account the following:
1. 15 before installation impregnate a new polyurethane foam epiploon with damping liquid.
2. Establish a rubber epiploon of 21 rods in a holder in such way that the inscription "bottom" on it was turned to the piston. Before installation of an epiploon on a rod moisten its internal surfaces interfaced to a rod with damping liquid.
3. 4 compression install the working cylinder with the valve knot pressed in it in the tank, then fill in damping liquid (320 cm3 for shock-absorbers with the cylinder with a diameter of 35 mm; 345 cm3 – with a diameter of 40 mm; 295 cm3 – for forward shock-absorbers), thus fill the cylinder up to the top, and pour out the rest of liquid in the tank.
Apply damping liquid according to tab. 1 to gas station of shock-absorbers. The volume of the filled-in liquid also has to correspond to the filling volume of the shock-absorber strictly. The admissible difference can make no more than ±5 cm3. Non-compliance with the specified recommendations will lead to violation of operation of the shock-absorber and even an exit it out of operation.
4. Insert a rod with the piston into the working cylinder, close the cylinder a guide and, having accurately straightened a tank epiploon on a guide end face, wrap a tank nut.
Pump over again assembled shock-absorber before installation on the car, moving a rod till that time until the effort becomes constants in all size of the course. It is necessary for removal of air from cavities of the working cylinder.